Name: ZPMC USA
Address: 4810 Belmar Blvd, Wall, NJ, 07753, US
Telephone: 732.677.2990

The Challenge

ZPMC USA was contracted to perform the full demolition of existing Fuji PLC and drive systems and installation of new TMEIC drive and Emerson IC695 RX3i PLC equipment on three STS cranes at VPA’s North NIT terminal. The existing Fuji PLC and drive equipment were outdated with no available replacement parts. Due to expansion efforts at NNIT, the three cranes had stood idle for several years.

Our Approach

Demolition and installation were strategically sequenced to maximize the use of existing crane infrastructure. Chair and SCR motor replacements were completed first while the crane retained functional motion, allowing ZPMC USA crews to use the trolley and maintenance hoist for rigging—eliminating the need for a rental crane. A custom steel platform was designed to extract oversized equipment through a temporary wall opening. New floor members were pre-cut to zero field-modification tolerance, enabling full floor installation in three days. Mechanical and electrical scopes were executed in parallel to maintain schedule. ZPMC USA engineers developed complete wiring books, structural drawings, and designed and built new contactor panel CA23 to support the updated drive architecture.

Outcome

Zero recorded safety incidents across all three cranes. Installation time was reduced from 12 weeks on the first crane to 8 weeks on the final crane, averaging 10 weeks across the project. TMEIC commissioning engineers reported no issues with field wiring, encoder feedback, or control integration. All power cable terminations and motor rotations were verified correct on the first check.